SDS SERIES DC SUBMERISIBLE PUMPS

Transcription

1 SDS SERIES DC SUBMERISIBLE PUMPS INSTALLATION MANUAL Kyocera Solar, Inc. / SOLARJACK, 7812 E. Acoma Drive, Scottsdale, AZ Telephone (800) FAX (480) info@kyocerasolar.com

2 Section 1 NOTE: Read sections 2 and 3 carefully before attempting to install this pump. Improper installation will void your warranty. SOLARJACK S SDS SERIES DC SUBMERSIBLE PUMPS SOLARJACK S SDS SERIES PUMPS are positive displacement, low voltage, DC powered, submersible pumps. Constructed of high quality marine bronze and stainless steel, these pumps were designed for corrosion free service in clean potable water. They can be installed in a well, cistern, lake, or stream. If used in conjunction with a pressure switch and tank, they may be used to pressurize a water system. The SDS-D series pump's light weight, only 14 pounds, and small size 3.8 outside diameter and length allows easy installation by hand into a 4 inside diameter well. The SDS-Q series pump, weighing 16.5 pounds and with a 4.3 outside diameter, also allows easy installation by hand into a 5 inside diameter well. Their stand-alone, pollution free and low noise operation makes them an ideal solution for remote home, wildlife, and stock watering problems, without violating the environment. Simplicity is the key feature of the SDS series pump line. They require no lubrication, they run on 12 volts or 24 volts DC and are completely serviceable. A variety of power sources may be used including solar panels, wind generator, batteries, or any combination of the three. (A SOLARJACK PC or PB series controller must be used as an interface between the power source and the pump on all systems). All new generation SDS series pumps are designed to meet the National Electric Code. The necessary changes have been made to all SOLARJACK pumps and controllers to meet this code. INSTALLATION INSTRUCTIONS Section PUMP 2.la Before installing the pump, measure the depth and static water level of the well. The static water level is the distance from the top of the casing to the water level in the well. This information is necessary in determining where to set the pump and the low water cut-off electrodes, if used. 12/06/99 2

3 2.lb Connect the drop pipe, safety rope, and sand shroud (if used) to the pump. Splice the drop wire to the motor lead and stretch it all out on the ground. See the wire splicing instructions in section 2.3 (Be careful not to get any dirt inside the drop pipe when stretching it out on the ground). If a saw is used to cut the drop pipe, make sure to clean the saw cuttings out of the pipe before Installation). Make the length of the pipe assembly a minimum of two feet longer than that of the static water level plus the anticipated draw down of the water level in the well. Never install the pump deeper than necessary. 2.lc Tie the drop pipe, drop wire, and safety rope together every ten feet with the wire ties or a high quality black electrical tape. (If the low water cut-off circuit- is used, attach the E-lS electrodes at the proper set points at this time also). Slide the well seal over the discharge end of the pipe, connect the discharge fitting, pull the drop wire through the seal, and connect the safety rope to the I-Bolt. 2.ld Lower the pump and pipe assembly into the well positioning the well seal over the top of the casing. 2.le Connect the discharge pipe to the fitting on top of the well seal and attach the pump wires and electrode wires (if used) to the controller. 2.2 PANEL SUPPORT STRUCTURE 2.2a The panel support structure should be located as close to the well as possible. This keeps the length of the drop wire and thus the voltage drop to a minimum. It must also be mounted in a good sunlight location away from trees, buildings, or anything that could cast a shadow on the panels. 2.2b Dig an 8 to 10 diameter hole to a depth of at least 24 inches. (This is for a 2-module support structure.) 2.2c Install the support structure pipe into the hole making sure that the pipe is plumb and then fill the hole with concrete. Allow 24 hours for the concrete to cure before installing the panels. 2.2d After the concrete has cured, install the panel support head (B) on the support structure pipe (E). Attach the upright (C) onto the head using the 5/8 bolt tabs (A). Attach the cross pieces (D) onto the upright using the 3/8 bolts. Attach the panels onto the cross pieces using the 1/4 bolts. (See separate instructions for other types of support structures and trackers.) 2.2e Cover the panels with a blanket or opaque material before wiring the panels to the controller and pump. CAUTION: PV PANELS GENERATE DC ELECTRICITY WHEN EXPOSED TO SUNLIGHT. 2.2-f Connect the panels and controller as illustrated in the wiring diagrams in the controller manual. 12/06/99 3

4 2.2g Remove the blanket from the panels and turn the switch on. If there is good sunlight the pump will start operating. 2.3 WIRE SPLICING 2.3a Prepare the cable by stripping the outer jacket insulation back 1-1/2 on the pump end and 2-1/2 on the incoming power end. (The insulation on the outer jacket of the long side is stripped back just enough to allow the smaller shrink tube to fit over the inner wire and allow the compression sleeve to be installed). 2.3b Prepare the inner wire ends by stripping the insulation to expose about 1/4 of each conductor. 2.3c Slip the large length of tubing over the entire cable and the smaller tubing over each wire on the long side. Splice the wires to the motor pigtail using the proper crimping tool and compression sleeves. Observe the colorcoding. 2.3d Position the small shrink tubing over each joint, making sure it is centered. Apply heat to the shrink tubing with a flame from a lighter or a propane torch. If using a torch, keep the flame moving to prevent burning the tubing. Proper shrinkage is reached when the tubing does not show any further reduction in size and the sealant has started to ooze at the ends. 2.3e Position the large shrink tubing over the entire joint making sure it is positioned over each side of the outer wire jacket. Apply heat until the proper shrinkage is reached. 2.3f To check proper sealing of the splice and wire installation immerse the splice and wire in a container of water for ten minutes and then take a resistance reading between the water and each of the cable conductors. Connect one ohmmeter lead to the conductor and the other lead to a piece of metal immersed- in the same water. Set the ohmmeter on the R x IOOK scale. The resistance should be two megohms (2 million ohms) or higher. A lower resistance indicates an insulation leak that must be corrected. 2.4 CONTROLLER ADJUSTING PROCEDURE NOTE: It is usually not necessary to adjust the controller since it has been pre-adjusted at the factory. 2.4a This procedure should be performed with the panels at their normal operating temperature at mid-day. To maintain peak output throughout the year, readjust the controller in very hot and very cold weather or as necessary. 2.4b With the system installed and pumping water, turn the panels away from the sun or cover the panels until the pump flow rate is reduced by approximately 50%. 2.4c Connect a DC volt-meter to the pump side of the controller. (LD+ and LD-) 2.4d Turn the "panel voltage adjusting pot", located on the upper left side of the controller, until the highest possible voltage is obtained. (This will also be the highest flow rate). 12/06/99 4

5 2.4e Return the panels to their normal position. The pump will then operate at its maximum output. 2.5 ELECTRODE INSTALLATION (OPTION) 2.5a With the pump and pipe stretched out on the ground and before installation into the well, (refer to step 2.1b) cut the electrode wire to the desired lengths and install all three E1-S electrodes in the proper locations. 2.5b The "ground electrode", terminal 3, must be in the water at all times and should be placed approximately two inches above the top of the pump. The "low water level electrode" terminal 1, is placed at the desired cut off point and is usually placed two to six inches above the ground electrode. The "high water level electrode", terminal 2, is placed at the desired turn-on level, but must be placed below the static water level and should be located no more than 20 feet from the low water electrode. NOTE: Wells with a high mineral content in the water and/or with cascading water above the electrodes may not be suitable for use with the low water cut-off circuit. Mineral deposits may collect on the electrodes insulating the circuits from the water. FOR PROPER PUMP PERFORMANCE Section 3 (Do not disassemble the pump during the warranty period. Any tampering will void your warranty). WARNING: IF THE PUMP IS DISASSEMBLED, USE EXTREME CAUTION AS THE MOTOR HOUSING MAY BE UNDER HIGH PRESSURE. 3.la For optimum pump performance make sure that the wire is sized properly for the length of run between the pump and the panels. Wire sized too small will cause a decreased output from the pump. Keep the distance from the PV panels to the pump as short as possible. For depths over 150 feet, higher wattage panels will help compensate for the additional losses in the longer wire lengths as well as the higher current requirements. 3.lb Make sure that the discharge pipe is sized properly for the length of run. Friction loss in a pipeline, especially over a long distance, will add head to the pump and thus reduce the flow rate. (Consult your SOLARJACK dealer for correct sizing for your system). 3.lc Never rest the pump on the bottom of the well, lake, cistern, etc. This can cause the pump to fill with mud and damage the diaphragm as well as reduce the flow of water past the motor and may cause overheating problems. Suspend the pump five feet or more above the bottom of the well. 3. 1d Use no larger than 1/2 drop pipe on SDS-D series pumps and 3/4 on SDS-Q series pumps. Because of the low flow rates the velocity of the water in larger pipes is not fast enough to carry small particles to the surface. These particles may settle inside the pump as well as the drop pipe causing pump damage as well as restricting the flow of water. If there is a known sand problem, a sand shroud or a screen is required. (Please note that the minimum well casing diameter for the SDS-D series shroud is 5 and the SDS-Q series shroud is 6 ). Damage to the pump caused by sand will void your warranty. It is 12/06/99 5

6 highly recommended that all pumps be installed with sand shrouds for maximum pump protection. 3.le Due to the aggressive action of DC power, it is essential that the wire splice at the pump be made correctly. This splice must be watertight. Improper sealing of this splice will cause poor pump performance and may cause damage to the controller. SOLARJACK S splice kit #S-703 is recommended for this watertight connection. 3.lf Never install the pump over 60 feet below the static water level. Excessive water pressure on the pump may cause seal damage and allow water to enter the motor housing. 3. 1g Never chlorinate a well while the pump is installed. Heavy concentrations of chlorine will damage the diaphragm and seals. 3.lh Never install the pump in a well that has or has had an oil lubricated line shaft turbine in it. Any drip oil remaining in the well will damage the diaphragm and seals. 3.li If the pump is used in a well over l00 feet deep, install a poppet type check valve on top of the pump. This will help relieve some of the pressure on the internal check valves and will keep any sediments from falling back into the pump. TROUBLESHOOTING Section PUMP DOES NOT RUN 4.la Check wiring diagrams for proper connections. 4.lb Check for proper panel, controller, and/or battery voltage with a volt meter. If our pump controller is being used, a quick look at the indicator lights will verify power coming from the panels going to the controller and power coming from the controller going to the pump. If the red light is on and the green light is not, connect a jumper wire across terminals 6 (PV-) and 7 (LD-). This will bypass the controller and will allow the pump to run panel direct. 4.lc Check the splice above the pump for proper connections. 12/06/99 6

7 4.ld Check for a broken wire leading to the pump. 4.le Check to see if the water level is above the top electrode, if the low water cut-off circuit is being used. (Turn dip switch #5 off and switch #6 on to bypass the low water cut-off circuit.) 4.lf Check for an open motor winding. (With an ohmmeter set on the R x 1 scale check between the two pump wires. Meter reading should be between.5 and 50 ohms. If the resistance is higher than this, disconnect the pump at the splice above the pump and check again). 4.lg Check the controller for proper adjustment. If the controller is adjusted wrong the pump flow rate will be low. If the voltage setting is higher than the input voltage, the controller will not turn on. (See section 2.4) 4.lh Check to see if the float switch, if used, is functioning properly. (Disconnect wires from terminals 4 & 5 to bypass the float circuit). 4.2 PUMP RUNS BUT DOES NOT PUMP WATER 4.2a Check to see if the pump is below the surface of the water. 4.2b Check for holes in the drop pipe. 4.2c Check for a plugged suction screen or pump full of mud, sand, or pipe cuttings. (If the pump is full of mud or sand, hold the pump upside down in a bucket of water and allow it to pump until all the mud clears). 4.2d Check for a plugged drop pipe or discharge pipe. 4.2e Check to see if the controller is adjusted properly. (See controller adjusting procedure section 2.4) 4.3 EXCESSIVE CURRENT DRAW (Over the normal amperage rating of the pump). 4.3a Check wiring diagrams for proper connections. 4.3b Check for skinned wires or faulty underwater splice. (See section. 2. 3d) 4.3c Check for a locked motor armature. (With the pump out of the well, bypass the controller and connect power directly to the motor leads. If the pump still does not run and the current is over 1.5 amps, the pump is in a locked or loaded rotor condition and must be repaired). NOTE: New pumps will draw slightly higher current for approximately 30 days. With the new heavy duty bearings and long life brushes the pump goes through a longer break-in period. 12/06/99 7

8 4.4 DECREASED PUMP OUTPUT 4.4a Check for a plugged suction screen. (Pull the pump and clean the screen). 4.4b Check for holes in the drop pipe. 4.4c Check for a restriction in the drop pipe. 4.4d Check to see if the water level in the well has dropped lower than normal or below the pump. 4.4e Check for mud or sand packed inside the pump or drop pipe. (If the pump is full of mud or sand, hold the pump upside down in a bucket of water and allow it to pump until all the mud clears. If the pipe is plugged with sand, clean the sand out of the pipe and install a SOLARJACK sand shroud around your pump). 4.4f Check the controller for proper adjustment. A controller being out of adjustment will cause decreased flow rates. (See section 2.4) 4.4g Check for the correct pump motor polarity. The black motor lead is always negative and the red motor lead is always positive. If these leads are reversed increased motor current and decreased pump flow rates will occur. 4.4h Check for dirt on the array or partial shadowing of the array. 4.5 PUMP RAPID CYCLING 4.5a If the low water cut-off circuit or high water cut-off circuit is being used, check to see if the high and low electrodes have been reversed. 4.5b If a pressure switch is being used, make sure a pressure tank is installed. 4.5c If a pressure tank is being used, make sure the tank is not water logged. 4.5d If a diaphragm pressure tank is being used, make sure the air pressure in the tank is 2 pounds less than the cut-in pressure, with the tank empty. WARNING: IF THE PUMP IS DISASSEMBLED USE EXTREME CAUTION AS THE MOTOR HOUSING MAY BE UNDER HIGH PRESSURE. REMEMBER, THIS VOIDS All WARRANTY. 12/06/99 8

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